I am going to build a couple of cajon's for my sons for Christmas.
These are basically a plywood box with 6 sides with a hole for sound
that is used as a drum. If one does a google image search for "cajon
drum" you will see many fine examples. But they all appear to have
nice sort of rounded corners and edges. They are made in some
variation of plywood generally 1/2 and 1/4 inch. Does anybody have
some good tips on how best to get this look when joining plywood? I
will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
inch for the front and back.
Thanks,
Jim
Jim, I assume you're trying to avoid tearout. I use two methods. The
best is to use a piece of sacrificial wood and cut both pieces at the
same time.the tearout occurs where the blade exits the wood on the cut.
A little experimentation will show you what to do. The second method is
to use duct tape over the cut (prior to the cut), which is removed
after the cut.
Also, make sure you use a good blade that is sharp.
jtpr wrote:
> I am going to build a couple of cajon's for my sons for Christmas.
> These are basically a plywood box with 6 sides with a hole for sound
> that is used as a drum. If one does a google image search for "cajon
> drum" you will see many fine examples. But they all appear to have
> nice sort of rounded corners and edges. They are made in some
> variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> some good tips on how best to get this look when joining plywood? I
> will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> inch for the front and back.
>
> Thanks,
> Jim
jtpr wrote:
> I am going to build a couple of cajon's for my sons for Christmas.
> These are basically a plywood box with 6 sides with a hole for sound
> that is used as a drum. If one does a google image search for "cajon
> drum" you will see many fine examples. But they all appear to have
> nice sort of rounded corners and edges. They are made in some
> variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> some good tips on how best to get this look when joining plywood? I
> will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> inch for the front and back.
>
> Thanks,
> Jim
>
Actually when I googled, I saw only 4 sided boxes plus a top and bottom.
I would use a solid corner with rabbeted sides so the plywood would fit
flush. The exposed corner of the wood could be rounded much cleaner than
trying to round off a piece of plywood. I made a chest this way and it
turned out nicely.
--
Gerald Ross
Cochran, GA
Half of the people in the world are
below average.
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Wow, thanks for all the ideas. I guess it is a four sided box with a
top and bottom. That's kind of what I meant by six sides. Anyway,
this is a picture of what I would like to end up with:
http://www.esflamenco.com/img/imagenesgrandes/25712723-147.jpg
Looking at the edges on this it appears that DonkeyHody's suggestion
would come the closest to the edges in the picture. Do I assemble and
glue up then run the router over the edges? Any technique here to
avoid tearing? I'm gonna use A4 Birch, seems to be the best I can find
in my area.
-Jim
jtpr wrote:
> Wow, thanks for all the ideas. I guess it is a four sided box with a
> top and bottom. That's kind of what I meant by six sides. Anyway,
> this is a picture of what I would like to end up with:
>
> http://www.esflamenco.com/img/imagenesgrandes/25712723-147.jpg
>
> Looking at the edges on this it appears that DonkeyHody's suggestion
> would come the closest to the edges in the picture. Do I assemble and
> glue up then run the router over the edges? Any technique here to
> avoid tearing? I'm gonna use A4 Birch, seems to be the best I can find
> in my area.
>
> -Jim
Thanks, Jim, but actually I like Gerald's idea better. If you have the
tools and skill for it, glue a 1/2+ X 1/2+ strip of some contrasting
wood to the edges of half your pieces. Let it stand a little proud on
the surface that will show. Then glue your box together so you have
these contrasting solid wood strips at each edge. Use a top bearing
flush cut router bit to trim the edges flush with the plywood, THEN use
a 1/4 round-over bit to soften the edge. It will look much better than
the rounded-over plywood.
But if you choose to just round the edges of the plywood like I
originally suggested, the only tearout problem you will have is at the
corner where you begin to go across the grain of the surface ply. Do
the edges that go with the grain first. Then, on the cross-grain part,
start your cut about an inch away from the corner and go backwards
(climb cut) that inch back to the corner. The 1/4 bit won't grab
enough to take the router away from you like a more aggressive bit
might.
Good Luck with your drums.
DonkeyHody
"If thy neighbor offend thee, buy each of his children a drum." -
Ancient Chinese Proverb
Would this be an example of what you are talking about?
http://www.taunton.com/finewoodworking/pages/w00119.asp
If it is, I like it. But if I'm using 1/2" ply on the top, bottom, and
2 sides and 1/4" on the front and back faces, as advised by drum
builders, wouldn't this be tough to accomplish?
Actually, now that I think about it, I would only have to do this on
the 2 sides and the top...
-Jim
jtpr wrote:
> I am going to build a couple of cajon's for my sons for Christmas.
> These are basically a plywood box with 6 sides with a hole for sound
> that is used as a drum. If one does a google image search for "cajon
> drum" you will see many fine examples. But they all appear to have
> nice sort of rounded corners and edges. They are made in some
> variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> some good tips on how best to get this look when joining plywood? I
> will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> inch for the front and back.
>
Baltic birch may be the better choice, it is birch all the way through,
most cabinet plywoods have poplar interior veneers. Luthiers use
plywood that is all hard maple, there is a luthier newsgroup under
the rec.crafts hierarchy.
--
FF
jtpr wrote:
> Would this be an example of what you are talking about?
>
> http://www.taunton.com/finewoodworking/pages/w00119.asp
>
> If it is, I like it. But if I'm using 1/2" ply on the top, bottom, and
> 2 sides and 1/4" on the front and back faces, as advised by drum
> builders, wouldn't this be tough to accomplish?
>
> Actually, now that I think about it, I would only have to do this on
> the 2 sides and the top...
>
> -Jim
Jim, I was thinking the whole box would be 1/2" ply. If two sides are
1/4", you have to get more creative. I don't have a ready idea for
that. Let it ferment a while.
DonkeyHody
Looks like I misunderstood the question.....Sorry.
Never Enough Money wrote:
> Jim, I assume you're trying to avoid tearout. I use two methods. The
> best is to use a piece of sacrificial wood and cut both pieces at the
> same time.the tearout occurs where the blade exits the wood on the cut.
> A little experimentation will show you what to do. The second method is
> to use duct tape over the cut (prior to the cut), which is removed
> after the cut.
>
> Also, make sure you use a good blade that is sharp.
>
>
> jtpr wrote:
> > I am going to build a couple of cajon's for my sons for Christmas.
> > These are basically a plywood box with 6 sides with a hole for sound
> > that is used as a drum. If one does a google image search for "cajon
> > drum" you will see many fine examples. But they all appear to have
> > nice sort of rounded corners and edges. They are made in some
> > variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> > some good tips on how best to get this look when joining plywood? I
> > will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> > inch for the front and back.
> >
> > Thanks,
> > Jim
I will post a drawing on Alt.binaries.pictures.woodworking showing what
I was talking about. The rabbits can be done with a jointer, router or
even with a table saw. After sanding level I then round over the corner.
Good luck, however you do it.
>
--
Gerald Ross
Cochran, GA
Half of the people in the world are
below average.
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Here's our first attempt
http://www.anneldavis.com/bobandanne/cajon.htm.
The corners were mitered with biscuits, then hand planed at a 45 degree
angle to ease each corner, after staining.
1/4" is too thick for the drum "skin". Use 1/8" baltic birch. We used
all baltic birch, 1/2" sides, 1/8" drum skin and 1/4" back.
The cajon we built has an awesome sound. We paid a lot of attention to
making the joints air tight.
Bob
Bob,
Awesome!!! That is exactly what I'm looking for. Would you be so kind
as to post dimensions? HxWxL and the radius of the sound hole? Is
there anyway that you know of to cut holes for biscuits without a
biscuit jointer? With both of the boys in college I am on a very tight
budget. Also, I noticed you glued the front skin on, in some examples
I have seen screws used, do you know why this is? They always seem to
be in certain pattern with more at the bottom then the top. When you
glued the skin and soundboard on did you have them flush with the edges
and then 45 them? In other words, was the OD of both of them the same
as the OD of the box?
Thanks a lot,
Jim
jtpr wrote:
> Do I assemble and
> glue up then run the router over the edges?
Yes
> Any technique here to
> avoid tearing?
Mount router in table and use fence with rounding over bit to insure
that your piece is following a straight reference (fence) rather than
use a bit with a pilot bearing and allowing the bit to follow the
assembled edge.
When starting at a corner, include a sacrifical piece to avoid tear out.
Have fun.
Lew
"jtpr" <[email protected]> wrote in message
>I am going to build a couple of cajon's for my sons for Christmas.
You can build them? I thought boys were born with them, no?
"jtpr" wrote:
>I am going to build a couple of cajon's for my sons for Christmas.
>These are basically a plywood box with 6 sides with a hole for sound
>that is used as a drum. If one does a google image search for "cajon
>drum" you will see many fine examples. But they all appear to have
>nice sort of rounded corners and edges. They are made in some
>variation of plywood generally 1/2 and 1/4 inch. Does anybody have
>some good tips on how best to get this look when joining plywood? I
>will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
>inch for the front and back.
Box joints, rounded over after assembly, are tough to beat IMHO.
Lew
In article <[email protected]>,
"jtpr" <[email protected]> wrote:
> I am going to build a couple of cajon's for my sons for Christmas.
> These are basically a plywood box with 6 sides with a hole for sound
> that is used as a drum. If one does a google image search for "cajon
> drum" you will see many fine examples. But they all appear to have
> nice sort of rounded corners and edges. They are made in some
> variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> some good tips on how best to get this look when joining plywood? I
> will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> inch for the front and back.
>
> Thanks,
> Jim
I like TomH's idea best so far.
In article <[email protected]>,
Lew Hodgett <[email protected]> wrote:
> "jtpr" wrote:
>
> >I am going to build a couple of cajon's for my sons for Christmas.
> >These are basically a plywood box with 6 sides with a hole for sound
> >that is used as a drum. If one does a google image search for "cajon
> >drum" you will see many fine examples. But they all appear to have
> >nice sort of rounded corners and edges. They are made in some
> >variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> >some good tips on how best to get this look when joining plywood? I
> >will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> >inch for the front and back.
>
>
> Box joints, rounded over after assembly, are tough to beat IMHO.
>
>
> Lew
You're right..and they're quick too...and easy to assemble.
I climb cut about an inch on end grain roundovers to avoid tear out as
it seems easier than the sacrificial piece.
On Tue, 29 Nov 2005 22:35:46 GMT, Lew Hodgett
<[email protected]> wrote:
>jtpr wrote:
>
>> Do I assemble and
>> glue up then run the router over the edges?
>
>Yes
>
>> Any technique here to
>> avoid tearing?
>
>Mount router in table and use fence with rounding over bit to insure
>that your piece is following a straight reference (fence) rather than
>use a bit with a pilot bearing and allowing the bit to follow the
>assembled edge.
>
>When starting at a corner, include a sacrifical piece to avoid tear out.
>
>Have fun.
>
>Lew
the current fine working has an article you might find interesting. The
author is making a carcase, but wanted mitered corners. He cut a dado in
each miter, layed the pieces together flat on the bench, outside up and used
packing tape to hold them together. Then flipped the assembly and spread
glue on each side. the tape acts as a clamp as the box is 'rolled' up.
Finally, and while the glue is wet, he inserted splines into the dadoes to
square eveything up.
Looked simpler than I am making it sound, though.
Harvey
<[email protected]> wrote in message
news:[email protected]...
> Here's our first attempt
> http://www.anneldavis.com/bobandanne/cajon.htm.
>
> The corners were mitered with biscuits, then hand planed at a 45 degree
> angle to ease each corner, after staining.
>
> 1/4" is too thick for the drum "skin". Use 1/8" baltic birch. We used
> all baltic birch, 1/2" sides, 1/8" drum skin and 1/4" back.
>
> The cajon we built has an awesome sound. We paid a lot of attention to
> making the joints air tight.
>
> Bob
>
I used this bit on 1/2' plywood to makd a open top roll around toy box for
my grandson.
Strong and looked great.
http://www.infinitytools.com/products.asp?dept=1062
.
.
"jtpr" <[email protected]> wrote in message
news:[email protected]...
>I am going to build a couple of cajon's for my sons for Christmas.
> These are basically a plywood box with 6 sides with a hole for sound
> that is used as a drum. If one does a google image search for "cajon
> drum" you will see many fine examples. But they all appear to have
> nice sort of rounded corners and edges. They are made in some
> variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> some good tips on how best to get this look when joining plywood? I
> will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> inch for the front and back.
>
> Thanks,
> Jim
>
My Suggestion:
A hexagon is 360 degrees divided by 6 sides = 60 divided by 2 = 30 degree
cuts.
I'd use the very high grade plywood I could buy (has better interior
layers).
Cut very clean angles using a good blade at 30 degrees.
You will need a spline in each joint or it will not have very much strength
(1/2" ply doesn't have much glue area at the joints).
This will require a jig to run each side through the table saw to cut a dado
at 90 degrees.
Glue up and lightly sand corners being careful not to sand through the top
layer.
"jtpr" <[email protected]> wrote in message
news:[email protected]...
>I am going to build a couple of cajon's for my sons for Christmas.
> These are basically a plywood box with 6 sides with a hole for sound
> that is used as a drum. If one does a google image search for "cajon
> drum" you will see many fine examples. But they all appear to have
> nice sort of rounded corners and edges. They are made in some
> variation of plywood generally 1/2 and 1/4 inch. Does anybody have
> some good tips on how best to get this look when joining plywood? I
> will be using Birch, probably 1/2 in for the sides, top and bottom, 1/4
> inch for the front and back.
>
> Thanks,
> Jim
>